Study On Cold Roll-Forming Technique Of Metal Sections

Cold roll-forming of metal sections is a significant field in advancing forming of strip metal, and the forming processes are influenced by many factors. So far, the determination of the forming techniques in cold roll-forming still mainly relies on the engineer's experience. Moreover, only through the way of "Trial and Error" can the regularity of technique be obtained. Therefore, it is of great importance, both theoretical and practical, to do research work on cold roll-forming of metal sections. The thesis focuses on small sections used in the automotive industry and their forming process--cold roll-forming. It not only briefly reviews the development history of roll-forming, its current domestic and overseas research condition, the traits of roll-forming sections, its application in the automotive industry as well as its prospect, but also compares the procedure of cold roll-forming with that of other forming methods. The process of roll-forming are explored, including how to determine the values of deformation length, the critical bending angle and the minimum bending radius in such a process and the plastic deformation of belt bars in the process, and based on which the calculation equation of energetic parameter is derived. The technique of cold roll-forming is approached in detail with its classification and principles being introduced. Furthermore, the designs of passes and roll shape and how to design the cold roll-forming procedures of sections and set their parameters are also respectively expounded. In response to the requirements of the clients, the section of an actual product is studied with the means of continuous-forming and the fixed-point method of conversion radius, and as a result the design of passes is figured out. In order to revise and improve this design, the whole process of cold roll-forming is stimulated on computer with the help of the software of Finite Element Analysis. By adjusting the related set of roll-forming mills the defects of the products are found out, and corresponding method for eliminating them are proposed. In the hope of directing the production of small sections in the automotive industry, the scientific design of passes is worked out by combining the theoretical analysis with the finite element analysis in accordance with the principles of cold roll-forming, thus the desirable high-quality sections being achieved through the combination of the theory with practice.